Optimizing the Geometric Parameters of Cutting Edge for the Finishing Machining of 30CR Alloy Steel

2019 ◽  
Vol 16 (08) ◽  
pp. 1850117
Author(s):  
Feng Jiang ◽  
Bicheng Guo ◽  
Tongkai Liao ◽  
Fuzeng Wang ◽  
Xin Cheng ◽  
...  
Keyword(s):  
Alloy Steel ◽  
Rake Angle ◽  
Geometric Parameters ◽  
Cutting Edge ◽  
Fe Model ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Tool Stress ◽  
Deformation Coefficient ◽  
Finishing Machining

In order to optimize the geometric parameters of cutting edge for the finishing machining of 30Cr alloy steel, a two-dimensional (2D) finite element (FE) model of orthogonal cutting was built with FE software AdvantEdge. The optimized methodology of the cutting edge geometric parameters was likewise proposed based on the simulated results. Thereafter, the geometric parameters of the cutting edge were optimized based on a comprehensive criterion that combines chip deformation coefficient and tool stress. The chip deformation coefficient indirectly determines the surface roughness, whereas tool stress determines tool wear, thereby affecting the dimensional precision of the components. The rake angle ranges from 12[Formula: see text] to 20[Formula: see text], while the cutting edge radius ranges from 12[Formula: see text][Formula: see text]m to 20[Formula: see text][Formula: see text]m in the optimization process. The optimal rake angle for the finishing machining 30Cr alloy steel is 16[Formula: see text], while the optimal cutting edge radius is 14[Formula: see text][Formula: see text]m with a given relief angle of 7[Formula: see text].

scholarly journals Multi-objective Optimization of Turning Tool Geometric Parameters Based on Kriging Model

2021 ◽  
Vol 2137 (1) ◽  
pp. 012046
Author(s):  
Jianxiang Sun ◽  
Huan Xie ◽  
Wei Zeng ◽  
Yaoyao Tong ◽  
Zhenyu Cai
Keyword(s):  
Rake Angle ◽  
Geometric Parameters ◽  
Cutting Edge ◽  
Cutting Performance ◽  
Performance Parameters ◽  
Multi Objective Optimization ◽  
Cutting Edge Radius ◽  
Multi Objective ◽  
Edge Radius ◽  
Relief Angle

Abstract Cutting performance parameters of turning tool in different geometric parameters are obtained using finite element model, and the Kriging models of cutting stress and temperature are constructed, taking the cutting performance parameters as training samples. The multi-objective optimization model of turning tool geometric parameters is established based on the constructed cutting performance Kriging models, in which the design variables are rake angle, relief angle and cutting-edge radius, the objective parameters are cutting stress and temperature. The multi-island genetic algorithm is used to obtain the optimum turning tool geometric parameters: rake angle γo is 10.59°, relief angle λs is 6.15°and cutting-edge radius γE is 0.73mm. The simulation results after optimization demonstrate that the corresponding cutting temperature reduces 263.1°C, cutting stress drops by 550.8MPa.

Finite Element Method Predicts the Distribution of Cutting Temperature in Diamond Turning

2007 ◽  
Vol 339 ◽  
pp. 100-105
Author(s):  
Wen Jun Zong ◽  
Dan Li ◽  
T. Sun ◽  
K. Cheng
Keyword(s):  
Temperature Field ◽  
Contact Area ◽  
Cutting Temperature ◽  
Rake Angle ◽  
Diamond Turning ◽  
Cutting Edge ◽  
Fe Model ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Distribution Shape

In this paper, a coupled thermo-mechanical FE model is proposed to simulate the cutting temperature’s distribution produced in diamond turning. Simulated results indicate that the heat converting from plastic work has prominent effects on the distribution shape of cutting temperature field, and with an increment in cutting velocity, the locating site of maximal cutting temperature shifts from the contact area between tool tip and chip root to the contact area between rake face and chip. Cutting edge radius has minute influence on the distribution shape of cutting temperature field, but the bigger the cutting edge radius is, the higher the maximum cutting temperature in cutting region. Rake angle also has slight effects on the maximal temperature when it is more than 10○. While clearance angle reaches to 6○, the maximum cutting temperature approaches the smallest.

Influences of Cutting Edge Radius on Cutting Deformation in High-Speed Machining Ti6Al4V

2011 ◽  
Vol 305 ◽  
pp. 47-52
Author(s):  
Shu Cai Yang ◽  
Min Li Zheng ◽  
Yi Hang Fan ◽  
De Qiang Zhang ◽  
Ying Bin Li
Keyword(s):  
High Speed ◽  
Equivalent Stress ◽  
Cutting Temperature ◽  
Chip Thickness ◽  
Cutting Edge ◽  
High Speed Machining ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Cutting Deformation ◽  
Deformation Coefficient

In order to obtain the influences of cutting edge radius on cutting deformation in high-speed machining Ti6Al4V, cutting temperature, equivalent stress distribution, the chip morphology and cutting deformation coefficient were analyzed in this paper. The results indicated that cutting edge changed the plastic flow of materials around tool tip and the actual tool rake angle, the tool-workpiece and tool-chip contact in cutting process which causes a greater impact on physical and mechanical performance in the given cutting conditions. When the cutting edge radius reached to 0.04mm,the cutting temperature and the equivalent stress existed mutations, which causes the mutation of chips. There was a chip thinning effect with the increase of the cutting edge radius. As the cutting edge radius increased, chip thickness and shear angle decreased, cutting deformation coefficient increased.

Development and manufacturing of customized milling cutters for individual tool-making industry

2017 ◽  
Vol 1 (82) ◽  
pp. 26-32
Author(s):  
J. Kopač ◽  
F. Pušavec
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
End Milling ◽  
Tool Material ◽  
Rake Angle ◽  
Cutting Edge ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Milling Tools ◽  
Material Cutting

Purpose: Purpose of this paper is to present results obtained during developing new cutting tools for individual tool industry. The aim of the research was to develop customized ball end milling tools with longer tool-life. Design/methodology/approach: to this study of development of new tools was over four successive sets of experiments, where the tool material, cutting edge preparation (cutting edge radius), rake angle and coating were selected for achieving longer tool-life. Tool-life was monitored over measuring tool wear on the flank face of the tool; maximum allowed tool wear was set to VB = 0.3 mm. Findings: of this study are showing that with right combination of the tool material, cutting edge radius, rake angle and appropriate coating, tool-life can be prolonged significant. Research (and practical) implications: implications are reflected in the substituting of all used milling tools from renowned manufacturers with these newly developed tools in this tool industry. Originality/value: of this paper is visible over significant improvement in tool-life of milling tools, especially for the company who will be using these tools in their production.

Evaluation of Cutting Forces During Single Pass Microtrenching of Poly (Methyl Methacrylate)

2014 ◽  
Vol 2 (4) ◽  
Author(s):  
Thomas P. James ◽  
Nathaniel B. Eckman ◽  
Amrit Sagar ◽  
Anil Saigal
Keyword(s):  
Thrust Force ◽  
Plastic Material ◽  
Chip Thickness ◽  
Material Model ◽  
Cutting Edge ◽  
Fe Model ◽  
Undeformed Chip Thickness ◽  
Cutting Edge Radius ◽  
Perfectly Plastic ◽  
Edge Radius

Research was conducted to evaluate a microtrenching process to create microchannels on the surface of poly (methyl methacrylate) (PMMA) for applications in tissue engineering. Experiments with a trenching tool included an exaggerated cutting edge radius (48 μm) to study the impact of a highly negative effective rake angle on forces during single pass microtrenching at subradius cutting conditions. During microtrenching, forces were measured by dynamometer and compared to a finite element (FE) model using an elastic-perfectly plastic material model for an undeformed chip thickness from 9 to 64 μm. During experiments, cutting was first observed when the ratio of undeformed chip thickness to cutting edge radius was 0.33. Measured and predicted values of thrust force exceeded cutting force up to an undeformed chip thickness equivalent to the cutting edge radius. The FE model predicted a linear trend in cutting force with feed (r = 0.99) and was substantiated by linear regression of experimental data (r = 0.99). However, at lower values of feed the model overestimated force, with a maximum difference of 42% at a feed of 22 μm. Thrust force was also predicted to be linear (r = 0.99), but at greater feed the experiments indicated a nonlinear decline in thrust force, resulting in a maximum difference of 27% at 64 μm. Finally, an analysis of nodal velocity plots from the FE model revealed a material stagnation zone developed along the cutting edge, rising from the workpiece surface in proportion to feed and then remaining fixed at 63 deg (stagnation angle) for all feeds greater than 35 μm. While the application of an elastic-perfectly plastic material model for PMMA was sufficient to predict microtrenching forces by the FE method, differences between predicted and measured thrust forces at greater undeformed chip thickness implies a more complex rheological model may add value.

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